US8221533B2 - Method to render surfaces water repellent - Google Patents
Method to render surfaces water repellent Download PDFInfo
- Publication number
- US8221533B2 US8221533B2 US13/177,035 US201113177035A US8221533B2 US 8221533 B2 US8221533 B2 US 8221533B2 US 201113177035 A US201113177035 A US 201113177035A US 8221533 B2 US8221533 B2 US 8221533B2
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- US
- United States
- Prior art keywords
- water
- acid
- alkylphosphonic acid
- water repellent
- stone
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
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Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/46—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with organic materials
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/32—Phosphorus-containing compounds
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/20—Resistance against chemical, physical or biological attack
- C04B2111/27—Water resistance, i.e. waterproof or water-repellent materials
Definitions
- This invention relates to a method to render stone, ceramic, and cementitious surfaces and structures water repellent by application or incorporation of at least one alkylphosphonic acid, either alone or co-mixed with low to medium molecular weight paraffinic liquids or solids.
- Granite, marble, slate, sandstone, limestone, and other materials can generally be regarded as stones. These materials are mined, cut to a desired shape, and optionally may be polished or tumbled to achieve a specific surface appearance. Ceramics, porcelain, and bricks can generally be regarded as ceramic compositions formed by combining powdered precursors in specific ratios followed by heating to high temperatures to fuse the component grains together and form a final shape.
- Ceramics, porcelain, and bricks can generally be regarded as ceramic compositions formed by combining powdered precursors in specific ratios followed by heating to high temperatures to fuse the component grains together and form a final shape.
- Grout, mortar, cement, and concrete can generally be regarded as cementitious materials formed by combining powdered precursors with other additives (such as sand, gravel, etc.) and water. On contact with water, chemical reactions occur to cause the overall composition to harden, or cure, into a final composition.
- Hydraulic cements are able to withstand immersion in water without short-term loss of strength. Examples of hydraulic cements include Portland and Rosendale cements. Non-hydraulic cements must remain dry to retain their strength. Examples of non-hydraulic cements include gypsum and Plaster of Paris.
- cementitious materials are widely used in structural applications, including roads, bridges, foundations, and buildings.
- concrete a composite of cement and aggregate
- exposure to liquid water is both frequent and undesirable, due to the impact on the structural strength of the cementitious material itself and on reinforcing additives, especially steel.
- the thickness of the film is a function of the application process. Insufficient application will result in films that are too thin and/or non-contiguous, while excessive application will result in films that are greater than the desired thickness. Such thick films often exhibit haze, surface mottling, and other cosmetically unattractive features.
- the present invention discloses a method to render stone, ceramic, and cementitious surfaces and structures water repellent that avoids the drawbacks of prior-art methods and products.
- the method of the present invention consists of contacting these surfaces and structures with an aqueous dispersion or solution of an alkylphosphonic acid or salt, either alone or in combination with a paraffinic liquid or solid.
- the alkylphosphonic acids react with divalent, trivalent, and tetravalent ions that comprise these substances, forming an insoluble, hydrophobic molecular layer on the surface of the grains composing the surface and structure of these materials.
- water repellency is defined as having a substantially reduced tendency to absorb liquid water. Simple tests for water repellency include liquid water contact angle measurement and liquid water weight gain/loss measurements.
- FIG. 1 is a graphical representation of a water permeation test showing a change in water height over time
- FIG. 2 is a graphical representation of a moisture sorption/loss sanded grout showing a percent weight change over time
- FIG. 3 is a graphical representation of a cement weight change after 42 hour water immersion.
- Phosphonic acids can be characterized as having the general formula: R—PO 3 H 2 , where R— is a hydrocarbon fragment and the compound possesses a carbon-phosphorus bond.
- the hydrocarbon fragment R— may be comprised of alkyl, cycloalkyl, or aryl moieties, and may be optionally substituted with other functional groups including but not limited to hydroxyl, carboxyl, chloro, bromo, fluoro, or amino.
- Phosphonic acids possess a number of useful characteristics than find utility in the present invention. First, they can be readily synthesized from commonly available chemicals. Second, the —PO 3 ⁇ 2 portion of the molecule is highly water soluble if in the free acid form or as a monovalent salt. Third, the —PO 3 ⁇ 2 portion reacts rapidly at room temperature with divalent, trivalent, and tetravalent ions, oxides, carbonates, and other salts to form water insoluble products. Fourth, the phosphorus-carbon bond that links the inorganic —PO 3 ⁇ 2 portion of the molecule to the organic portion is chemically, thermally, and photochemically stable.
- the organic portion of the phosphonic acid comprises linear alkyl chains
- the alkyl chains spontaneously align to form a dense contiguous surface. Because the alkyl chains are themselves hydrophobic, the exposed surface is consequently rendered hydrophobic.
- the resulting alkylphosphonate divalent, trivalent, and tetravalent salts are insoluble and thermodynamically very stable, they cannot be removed by treatment with common cleaning materials, including mild acids and bases (for example, ammonia, vinegar, bleach, sodium bicarbonate, etc.).
- the phosphonic acids have little or no tendency to react with materials that are not substantially comprised of divalent, trivalent, or tetravalent ions, there is little or no tendency to adhere to other surfaces, such as wood or plastic.
- the mechanism of action is reaction with surface ions, the resulting modified surface has little or no tendency to react further with additional phosphonic acid; hence repeated applications will not result in increasing thickness of the residue.
- phosphonic acids are not polymeric and the method of application does not result in the formation of a polymeric film, removal and disposal of excess product is straightforward. Typically, disposal can be accomplished simply by pouring the excess product and any rinse water down a drain.
- any material that makes its way into the soil will react with these ions and be rendered non-leachable.
- any material disposed into a waste sewer will be removed during normal processing in a waste-water facility, where filtering with Fuller's Earth or treatment with alum is almost universally practiced.
- the alkyl phosphonic acids preferred in the present invention themselves possess a low order of toxicity and have no known biocidal or herbicidal properties.
- the alkylphosphonic acids of the present invention are non-volatile, water dispersible and only mildly acidic, hence do not represent a breathing or contact hazard during application.
- marble is comprised predominantly of calcium carbonate.
- Slate is comprised primarily of compressed clay, which in turn is comprised of aluminosilicates.
- Granite is also comprised primarily of aluminosilicates.
- Ceramic tile is comprised of aluminates and aluminosilicates.
- Portland cement which is the basic material used in grout, is comprised of calcium and magnesium hydroxides and aluminosilicates.
- the phosphonic acids of present invention are alkyl phosphonic acids, and preferably linear alkyl phosphonic acids, wherein the alkyl group does not possess any functional group that would render it hydrophilic.
- Alkyl phosphonic acids of the present invention possess both the desired hydrophobicity imparted by the alkyl portion of the molecule and a tendency to form a densely packed surface. The tendency to form a densely packed surface is driven by Van der Waals attraction between the —CH 2 — groups in the alkyl chain. The effect of alkyl chain length on the tendency to form a densely packed surface can be readily seen in the effect of alkylphosphonic acid chain length on water contact angles.
- Water contact angle measurement is a simple, direct way of determining the hydrophilicity or hydrophobicity of a surface.
- Very hydrophilic surfaces possess low water contact angles, typically between 0 and 20 degrees.
- Highly hydrophobic surfaces possess very high water contact angles, typically greater than about 100 degrees.
- the water contact angles are approximately 40, 50, 90, 120, 120, and 120 degrees.
- An untreated alumina surface itself had a water contact angle less than about 20 degrees.
- linear alkyl phosphonic acids with more than six carbons are preferred.
- alkylphosphonic acid dispersed in water is not especially critical. However, while amounts greater than 10 wt % can be readily dispersed in water, such dispersions deliver more alkylphosphonic acid than is generally necessary. Conversely, dispersions containing less than about 0.1 wt % alkylphosphonic acid may deliver less alkylphosphonic acid than is sufficient. In a preferred embodiment, an aqueous dispersion comprising about 0.2-5 wt % octylphosphonic acid in water is applied at room temperature to the surface or structure to be treated.
- the amount applied or the specific method of application is not critical. Application can for example be by spraying, dipping, pouring onto the surface, or wiping on with an absorbent sponge or cloth. After application, the water is allowed to evaporate. In some instances a second application may be required, especially when the surface is highly porous and/or insufficient phosphonic acid was available to react with all the surface metal ions. While not critical to the efficacy of this invention, the treated surface may optionally be heated to speed evaporation of water. To test for effectiveness of the surface treatment, a drop of water can be applied to the treated surface. On well-treated surfaces the water drop will remain on the surface and not spread out over time.
- an alkylphosphonic acid dispersion is mixed with a powdered cementitious material which is then formed into a final shape and allowed to cure. After curing, the resulting cementitious material is rendered water repellent throughout the structure.
- the binding of the octylphosphonic acid will be unimpeded, but after reaction with the alkylphosphonic acid to form a hydrophobic surface, the paraffinic dispersion will adhere to the hydrophobic surface. Unlike the mono-molecular alkylphosphonate layer, the paraffin will form a relatively thick layer that can visibly alter the appearance of the surface.
- aromas such as lemon oil, orange oil, or other aromas may be added to the water dispersion to enhance the aroma during application and drying. Because 2 wt % alkylphosphonic acid is about as acidic as lemon juice, these aromas are stable in the product.
- the alkylphosphonic acid may be partially neutralized with an amine such as ammonia, ethanolamine, diethanolamine, etc. or a basic alkali salt such as for example sodium hydroxide, sodium bicarbonate, potassium acetate, etc.
- an amine such as ammonia, ethanolamine, diethanolamine, etc.
- a basic alkali salt such as for example sodium hydroxide, sodium bicarbonate, potassium acetate, etc.
- Partial neutralization also enhances the water dispersibility of the alkylphosphonic acid, and may be preferred where longer chain alkylphosphonic acids are selected.
- hydrophobicity can extend well below the physical surface of the substrate. Consequently, even if the surface is highly abraded by wear the underlying grains of material can retain water repellency.
- a ceramic tile counter with 1 ⁇ 4′′ wide black grout lines was tested for water repellency.
- a drop of water was place on the grout line. The water drop immediately absorbed into the grout and spread until over 1 inch of grout was wetted.
- a 2 wt % dispersion of octylphosphonic acid in water was applied by flooding the grout surface. After this application had dried for about 30 minutes, the surface was treated again and was wiped lightly with a paper towel. After drying, the appearance of the treated and adjacent untreated grout was identical. Likewise, there was no change in the appearance of the treated tile adjacent to the treated grout.
- Application of a drop of water to the treated grout resulted in a bead of water that did not absorb or spread into the grout.
- Example 3 was repeated, but using a slate tile. Again there was no evidence of water penetration after eight hours of submersion.
- Example 1 A section of the treated tile surface from Example 1 was rubbed vigorously for 30 seconds with 0000 steel wool. The abraded surface was then rinsed with water and allowed to air dry. After drying, a droplet of water was applied to the abraded surface. The water contact angle of the droplet was identical to the angle observed for a similar droplet placed on a portion of the treated tile surface that had not been abraded.
- a section of the treated tile surface from Example 1 was rubbed vigorously for 30 seconds with a paper towel soaked in 3 wt % ammonia water. The rubbed surface was then rinsed with water and allowed to air dry. After drying, a droplet of water was applied to the rubbed surface. The water contact angle of this droplet was identical to the angle observed for a similar droplet placed on a portion of the treated tile surface that had not been rubbed.
- Example 1 A section of the treated tile surface from Example 1 was rubbed vigorously for 30 seconds with a paper towel soaked in 5 wt % acetic acid/water solution. The rubbed surface was then rinsed with water and allowed to air dry. After drying, a droplet of water was applied to the rubbed surface. The water contact angle of this droplet was identical to the angle observed for a similar droplet placed on a portion of the treated tile surface that had not been rubbed.
- a section of the treated tile surface from Example 1 was rubbed vigorously for 30 seconds with a paper towel soaked in water containing a liquid detergent. The rubbed surface was then rinsed with water and allowed to air dry. After drying, a droplet of water was applied to the rubbed surface. The water contact angle of this droplet was identical to the angle observed for a similar droplet placed on a portion of the treated tile surface that had not been so rubbed.
- a 1 pound sample of powdered, sanded grout mix was blended with 80 grams of a 4% solution of octylphosphonic acid ethanolamine salt.
- a separate 1 pound sample of powdered, sanded grout mix was blended with 80 grams of tap water. Both were poured into separate molds and allowed to cure. After 72 hours each was tested for water repellency. Water placed on the surface of the treated grout formed beads of water, whereas water placed on the surface of the untreated grout was rapidly absorbed.
- a solution of 2% octylphosphonic acid ethanolamine salt containing 15% of a paraffin wax emulsion was coated onto one half of a dark gray slate tile. After drying, the treated surface exhibited enhanced gloss as well as exceptional water repellency.
- the base of two concrete containers 10 inches square and 8 inches deep were sealed with Portland cement.
- the inside surfaces of one container was treated twice with a 2% solution of octylphosphonic acid ethanolamine salt. Both were then filled to a depth of 7.0 inches with tap water and the top surface covered with a polyethylene film (to prevent evaporation from the open top of the containers).
- the water height was monitored over time. The change in water height is illustrated in FIG. 1 .
- grout prepared according to the method of this invention not only absorbs far less liquid water than a comparison grout, but it also does not exhibit any tendency to retain moisture.
- a 1 lb sample of gypsum-based powdered joint compound was mixed with water containing 2% octylphosphonic acid ethanolamine salt according to the manufacturer's directions.
- a second 1 lb sample of the same powdered gypsum was mixed with an equal amount of water. Both samples were poured into 2′′ diameter cardboard tubes and allowed to set. After setting, the tubes were removed and discs cut from the center of the tubes. Water droplets were placed onto the center of the example and comparison discs. On discs prepared using water containing 2% octylphosphonic acid ethanolamine salt the water droplets beaded up and did not absorb into the gypsum. On comparison discs, the water droplets were rapidly absorbed.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Organic Chemistry (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Aftertreatments Of Artificial And Natural Stones (AREA)
Abstract
Description
R—PO3H2,
where R— is a hydrocarbon fragment and the compound possesses a carbon-phosphorus bond. The hydrocarbon fragment R— may be comprised of alkyl, cycloalkyl, or aryl moieties, and may be optionally substituted with other functional groups including but not limited to hydroxyl, carboxyl, chloro, bromo, fluoro, or amino.
Claims (11)
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US13/177,035 US8221533B2 (en) | 2010-07-20 | 2011-07-06 | Method to render surfaces water repellent |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US36597510P | 2010-07-20 | 2010-07-20 | |
| US13/177,035 US8221533B2 (en) | 2010-07-20 | 2011-07-06 | Method to render surfaces water repellent |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| US20120017801A1 US20120017801A1 (en) | 2012-01-26 |
| US8221533B2 true US8221533B2 (en) | 2012-07-17 |
Family
ID=45492496
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US13/177,035 Expired - Fee Related US8221533B2 (en) | 2010-07-20 | 2011-07-06 | Method to render surfaces water repellent |
Country Status (5)
| Country | Link |
|---|---|
| US (1) | US8221533B2 (en) |
| CA (1) | CA2804510A1 (en) |
| GB (1) | GB2495043A (en) |
| MX (1) | MX2013000665A (en) |
| WO (1) | WO2012012199A1 (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR20210143219A (en) * | 2019-03-22 | 2021-11-26 | 롬 앤드 하스 캄파니 | Water resistance for organic façades |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3794506A (en) * | 1972-10-02 | 1974-02-26 | Dow Chemical Co | Cementitious compositions containing phosphonic acid |
| US5124289A (en) * | 1986-12-29 | 1992-06-23 | Aluminum Company Of America | Surface treated permeable inorganic membranes and process of making same |
| US20070036973A1 (en) * | 2005-08-11 | 2007-02-15 | Bruner Eric L | Composition for treating glass fibers and treated glass fibers |
| US20070092640A1 (en) * | 2005-10-24 | 2007-04-26 | Bruner Eric L | Process for applying organophosphorus-based layers on substrates |
Family Cites Families (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7658797B2 (en) * | 2005-03-22 | 2010-02-09 | Nova Chemicals Inc. | Lightweight concrete compositions |
-
2011
- 2011-07-06 US US13/177,035 patent/US8221533B2/en not_active Expired - Fee Related
- 2011-07-06 GB GB1300341.3A patent/GB2495043A/en not_active Withdrawn
- 2011-07-06 CA CA2804510A patent/CA2804510A1/en not_active Abandoned
- 2011-07-06 MX MX2013000665A patent/MX2013000665A/en active IP Right Grant
- 2011-07-06 WO PCT/US2011/043017 patent/WO2012012199A1/en active Application Filing
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3794506A (en) * | 1972-10-02 | 1974-02-26 | Dow Chemical Co | Cementitious compositions containing phosphonic acid |
| US5124289A (en) * | 1986-12-29 | 1992-06-23 | Aluminum Company Of America | Surface treated permeable inorganic membranes and process of making same |
| US20070036973A1 (en) * | 2005-08-11 | 2007-02-15 | Bruner Eric L | Composition for treating glass fibers and treated glass fibers |
| US20070092640A1 (en) * | 2005-10-24 | 2007-04-26 | Bruner Eric L | Process for applying organophosphorus-based layers on substrates |
Also Published As
| Publication number | Publication date |
|---|---|
| US20120017801A1 (en) | 2012-01-26 |
| GB2495043A (en) | 2013-03-27 |
| GB201300341D0 (en) | 2013-02-20 |
| CA2804510A1 (en) | 2012-01-26 |
| MX2013000665A (en) | 2013-05-20 |
| WO2012012199A1 (en) | 2012-01-26 |
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